Planar EMI inductor

Abstract

A power bus bar assembly comprising planar electromagnetic interference (EMI) inductors. An exemplary power bus bar assembly or planar inductor comprises upper and lower E-E magnetic cores, and upper and lower flat bus bars that are insulated from each other. The bus bars have a plurality of core cut-outs that allow the cores to pass through them. The core cut-outs form an electrical path through the E-E cores that forms a turn that provides a predetermined amount of inductance. The bus bars may be arranged to form turns in the same direction or opposing directions that provide for a common mode and differential mode inductors, respectively. Different core materials and stacking of multiple cores may be used to improve the frequency response of the inductor.

What is claimed is:  
     
       1. A power bus bar assembly comprising: 
       a planar inductor comprising:  
       upper and lower E-E magnetic cores; and  
       upper and lower flat bus bars that are insulated from each other and each of the flat bus bars having a plurality of core cut-outs that allow the cores to pass through them, and wherein the core cut-outs define a serpentine-shaped portion in each of the upper and lower flat bus bars to provide an electrical path through the E-E cores that forms turns to provide a predetermined amount of inductance.  
     
     
       2. The assembly recited in  claim 1  wherein the upper and lower flat bus bars comprise stamped bus bars. 
     
     
       3. The assembly recited in  claim 1  wherein the upper and lower flat bus bars that are insulated using an insulating coating. 
     
     
       4. The assembly recited in  claim 1  wherein the upper and lower flat bus bars that are insulated using an intermediate insulating member between the bus bars. 
     
     
       5. The assembly recited in  claim 1  wherein each bus bar further comprises a plurality of cutouts that are generally aligned with holes in the other bus bar that are used to secure terminals of power switching devices to the bus bars. 
     
     
       6. The assembly recited in  claim 1  wherein the turns of the electrical path in the upper flat bus bar are in the same direction as the turns of the electrical path in the lower flat bus bar to provide for a common mode inductor. 
     
     
       7. The assembly recited in  claim 1  wherein the turns of the electrical path in the upper flat bus bar are in an opposite direction as the turns of the electrical path in the lower flat bus bar to provide for a differential mode inductor. 
     
     
       8. The assembly recited in  claim 1  wherein the upper and lower E-E magnetic cores comprise different core materials. 
     
     
       9. The assembly recited in  claim 1  wherein the upper and lower E-E magnetic cores comprise multiple cores. 
     
     
       10. The assembly recited in  claim 1  wherein the upper and lower E-E magnetic cores comprise multiple cores that comprise different core materials. 
     
     
       11. A planar inductor comprising: 
       upper and lower E-E magnetic cores; and  
       upper and lower flat bus bars that are insulated from each other and each of the upper and lower flat bus bars having a plurality of core cut-outs that allow the cores to pass through them, and wherein the core cut-outs define a serpentine-shaped portion in each of the upper and lower flat bus bars to provide an electrical path through the E-E cores that forms turns to provide a predetermined amount of inductance.  
     
     
       12. The inductor recited in  claim 11  wherein the upper and lower flat bus bars comprise stamped bus bars. 
     
     
       13. The inductor recited in  claim 11  wherein the upper and lower flat bus bars that are insulated using an insulating coating. 
     
     
       14. The inductor recited in  claim 11  wherein the upper and lower flat bus bars that are insulated using an intermediate insulating member between the bus bars. 
     
     
       15. The inductor recited in  claim 11  wherein each bus bar further comprises a plurality of cutouts that are generally aligned with holes in the other bus bar that are used to secure terminals of power switching devices to the bus bars. 
     
     
       16. The inductor recited in  claim 11  wherein the turns of the electrical path in the upper flat bus bar are in the same direction as the turns of the electrical path in the lower flat bus bar to provide for a common mode inductor. 
     
     
       17. The inductor recited in  claim 11  wherein the turns of the electrical path in the upper flat bus bar are in an opposite direction as the turns of the electrical path in the lower flat bus bar to provide for a differential mode inductor. 
     
     
       18. The inductor recited in  claim 11  wherein the upper and lower E-E magnetic cores comprise different core materials. 
     
     
       19. The inductor recited in  claim 11  wherein the upper and lower E-E magnetic cores comprise multiple cores. 
     
     
       20. The inductor recited in  claim 11  wherein the upper and lower E-E magnetic cores comprise multiple cores that comprise different core materials.